Daihen OTC Welbee Inverter W400 Owner'S Manual Download Page 148

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ARTS

IST

EFERENCE

ATERIALS

HAPTER

10-2

R1 to 4

6100-052

Surge absorber

TND14V-911KB0LLAA0

R5 to 10

100-0234

Carbon resistor

RD20S 1K

Ω

TR1 to 4

R12,13

100-1430

Metal film resistor

RPM200Z 5

Ω

R18

100-0662

Thermistor

EC2F103A2-40113

R19a,b

100-1432

Winding resistor

FH50 471J/RO

R20,21

100-0234

Carbon resistor

RD20S 1K

Ω

TR3,4

R22

100-1571

Winding resistor

CS1P 100

Ω

R23

4509-918

Cement resistor

40SH 200

Ω

R24

4509-704

Carbon resistor

RD1/4W 1k

Ω

R28,29

100-1949

Fixed metal oxide film resistor

MOS1CT52A104J

R30,31

4509-905

Cement resistor

MHR20A513J1

R33,34

Cement resistor

RH220 10

Ω

R35

4509-704

Carbon resistor

RD1/4W 1k

Ω

TR12

R36

100-1430

Metal film resistor

RPM200Z 5

Ω

R43

4508-317

Carbon resistor

RD1/2S 3k

Ω

TR11

R50 to 57

4508-317

Carbon resistor

RD1/2S 3k

Ω

TR5 to 8

R65

4509-109

Fixed metal oxide film resistor

RS1B 51k

Ω

R66,67

100-1430

Metal film resistor

RPM200Z 5

Ω

C1 to 4

4517-459

Ceramic capacitor

DEBF33D103ZA3B

4518-526

Film capacitor

EM351200D0BA1HP

Film capacitor

FHC(180)2000V223J

100-1572

Film capacitor

FHC(180)2000V103J

C10

100-0227

Film capacitor

0.47µF 50V

C12,13

100-1871

Film capacitor

US20X223JBASA

C21a to c

4517-401

Ceramic capacitor

CS17-F2GA103MYGSA

C22a to c

4517-401

Ceramic capacitor

CS17-F2GA103MYGSA

C23 to 26

Film capacitor

US63Y224JAASA

CON1

100-1435

Receptacle

DPC25-10BP

CON2

4730-010

Receptacle

DPC25-6BP

CON3

4730-192

VL connector

VLP-03V

CON4

4730-193

EL connector

ELP-06P

CR1

4341-139

Relay

G2R-1-T DC24V

TM5

4739-141

Terminal board

T-3 (Black)

TM6

100-2234

Terminal

DG15HS-1.2-04P-17-
100A(H)

DCV1

K5791B00

Power supply

K5791B00

DCV2

K5791C00

Power supply

K5791C00

PCB1

P30205P00

Printed circuit board

P30205P00

(*1)

4341-206

Relay

G6A-274P DC24V

With PCB1

PCB2

P30086R00 Printed circuit board

P30086R00

FRONT PANEL

100-1421

Encoder

EVEGA1F2524B

With PCB2

PCB3

P30133Q00 Printed circuit board

P30133Q00

PCB4

P30087Q00 Printed circuit board

P30087Q00

PCB5

P30086V00

Printed circuit board

P30086V00

PCB6

P30086V00

Printed circuit board

P30086V00

PCB7

P30205M00 Printed circuit board

P30205M00

PCB8

P30086T00

Printed circuit board

P30086T00

PCB9

P30087T00

Printed circuit board

P30087T00

PCB10

P30086S00

Printed circuit board

P30086S00

REAR PANEL

PCB11

P30205V00

Printed circuit board

P30205V00

PCB12

P30205S00

Printed circuit board

P30205S00

(1)

P30086G01 Mold cover

P30086G01

Upper side cover

(2)

P30086G02 Mold cover

P30086G02

Under side cover

Code

Part No.

Product Name

Specifications

Q’ty

Remarks

Summary of Contents for OTC Welbee Inverter W400

Page 1: ...d this instruction manual thoroughly for safe and proper use of the product August 2016 Manual No P30205 1 Model WB W400 Welbee Inverter W400 OWNER S MANUAL AC DC Pulsed MIG Welding Power Source DAIHE...

Page 2: ......

Page 3: ...nual hereafter referred to as this manual explains the following points for safe use of the product Caution regarding the product Welding operation setting method Daily maintenance cleaning inspection...

Page 4: ...ure that installation operation maintenance of the welding power source and welding machine is performed by qualified personnel with sufficient knowledge and skills If this manual is lost or damaged i...

Page 5: ...del manufacture year serial number and software version number Refer to the diagram below for product information Attachment location and content of nameplate may vary depending on the purchased produ...

Page 6: ...h lifting lug 3 6 CHAPTER 4 CONNECTION 4 1 Precautions for Connection Procedure and Grounding 4 1 4 2 Connecting the Welding Power Source 4 2 4 2 1 Connection of cable at output side 4 3 4 2 2 Connect...

Page 7: ...ction 7 4 7 2 1 Setting welding result control function 7 4 7 2 2 Details of welding control items 7 5 7 3 Data Backup Utilization of data 7 9 7 3 1 Setting of welding conditions internal functions 7...

Page 8: ...vi MEMO...

Page 9: ...n for the symbols are as follows Make sure to fully understand the content before beginning operation The below symbols are categorized by the degree of possible hazard and damage The below symbols ar...

Page 10: ...allowed unauthorized access near the welding power source or work areas Only authorized personnel or person with full understanding and experience of the welding power source must perform installation...

Page 11: ...ource and wait three minutes or more The capacitors may be still charged even after the input power is cut Make sure that there is no charged voltage before starting the work Wear dry insulating glove...

Page 12: ...For preventive measure from falling due to anoxia apply lifelines such as a safety belt For the welding operation in a narrow space perform the operation with the trained supervisor Periodically inspe...

Page 13: ...on gas pipe and closed containers such as tanks or drums Performing arc welding on flammable object such as fuel tank may cause explosion Furthermore welding on closed container such as tanks and pipe...

Page 14: ...ay from the gas discharge port Keep protective cap in place over valve except when gas cylinder is in use or connected for use Do not place the gas cylinder under high temperature Protect compressed g...

Page 15: ...g by customer is out of the warranty scope When welding or watching a welder work wear face shield with a proper shade of filter See ANSI Z 49 1 listed in PRINCIPAL SAFETY STANDARDS to protect the fac...

Page 16: ...Electrical Code NFPA Standard 70 from National Fire Protection Association Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association Code for Safety in Welding an...

Page 17: ...Three phase Rated frequency 50 60 Hz Rated input voltage 400 V Input voltage range 400 V 15 Rated input 21 4 kVA 17 0 kW Rated input current 31 A Rated output current 400 A 350 A Rated load voltage 3...

Page 18: ...1 Al 99 1 0 1 2 1 6 2 Al Mg 1 0 1 2 1 6 2 Cu Si 0 8 1 0 1 2 2 INCONEL 1 2 2 CrNi 1 0 1 2 2 MIG 2 5 CO2 1 2 CrNi 1 0 1 2 2 CrNi Ferr 1 0 1 2 2 MIG 2 O2 1 3 CrNi 1 0 1 2 2 MAG 20 CO2 1 4 G3Si1 1 0 1 2 2...

Page 19: ...a mixing gas other than those with the following mixing ratios is used 1 1 MIG gas Aluminum Aluminum bronze Silicon bronze Argon Ar 100 1 2 MIG gas mild steel Argon Ar 97 5 Oxygen O2 2 5 1 3 MIG gas s...

Page 20: ...rnout of the welding power source The rated duty cycle of the welding power source is the following Operation cycle at duty cycle of 60 400 A 40 350 A 100 for DC Rated duty cycle of 60 means the power...

Page 21: ...on with the specified wire feeder Connecting to any equipment other than specified may cause failure of the welding power source No Name Suppliedunit 1 Optional accessories Remarks 1 Gas regulator To...

Page 22: ...ol cable for wire feeder 1 5 m 2 6 Power cable for torch side 2 m 2 7 Power cable for base metal side 2 m 2 8 Shielding gas To be prepared by the customer 2 2 2 Accessory not supplied 9 Digital remote...

Page 23: ...elding torch 3 Gas hose 3 m 2 4 Power cable for base metal side 2 m 2 5 Shielding gas To be prepared by the customer 2 2 2 Accessory not supplied 6 Digital remote control optional 2 7 Analog remote co...

Page 24: ...cessories Remarks 1 Welding electrode holder To be prepared by the customer 2 2 2 Accessory not supplied 2 Power cable 38mm2 or more 2 3 Power cable for base metal side 2 m 2 4 Digital remote control...

Page 25: ...er optional items Following items are optionally available including remote control and voltage detection cable Product name Part No Model Remarks Analog remote control K5416Z00 Includes 3 m cable Dig...

Page 26: ...tension cable may cause an unstable arc Use extension cables with suitable length Unnecessarily long extension cable may cause an unstable arc No Product name Model 5 m 10 m 15 m 20 m 1 Gas hose BKGG...

Page 27: ...of the welding power source 2 3 1 Front panel The section explains the front section of the welding power source Socket for wire feeder Socket for analog remote control Output terminal Torch side Outp...

Page 28: ...n explains the rear section of the welding power source Blind bush for drawing externally connecting wire Cover for external connections Connector for connecting CAN Printed circuit board Terminal blo...

Page 29: ...eration Setting to an extremely high output voltage may result in damage to the welding power source When the welding power source is used in a humid environment such as construction site or location...

Page 30: ...nt When welding is required in tank boiler reaction tower or hold of a ship closed space or any other places of poor ventilation ensure to provide ventilation equipment Condition of ventilation equipm...

Page 31: ...20 C Location with an altitude of less than 1000 m Location with an incline of 10 or less Location with no metallic foreign body such as spatter entering the welding power source Installation distance...

Page 32: ...lding power source Welding cables Do not use an unnecessarily long cable Place a base metal cable and a torch side cable as closely as possible Equipotential bonding Bonding of all metallic objects in...

Page 33: ...nd floor Do not apply strong shock to the welding power source when placing it on the floor It may cause damage to the welding power source Since large current abruptly flows inside the welding power...

Page 34: ...dents be sure to observe the following For operation of a crane or hoisting make sure that a qualified personnel operate them with attention to the surrounding area for safety Use the lifting tool suc...

Page 35: ...parts of the welding power source Have a qualified electrical engineer ground the case of the welding power source and base metal or jig electrically connected in accordance with local regulation Mak...

Page 36: ...ource until confirming the completion of connection work Otherwise electric shock may occur Connection of cable at output side 4 2 1 Connection of cable at output side Connection of wire feeder 4 2 2...

Page 37: ...ighten them in the clockwise direction 2 Connect the power cable for torch side to the output terminal torch side Connect the connectors as same as above Connection for cable at output side is complet...

Page 38: ...ol cable 10 cores to the socket for the wire feeder Fit the concave part of the connector and convex part of the socket for secure connection and tighten the knurled screws in the clockwise direction...

Page 39: ...re connection and tighten the knurled screws in the clockwise direction 2 When using the water cooled welding torch connect the water feeding hose and condensing hose of the welding torch to the wire...

Page 40: ...ection cable for base metal side can also be connected to the direct voltage detection terminal for base metal of the welding power source When using the welding power source by lifting with hoisting...

Page 41: ...r reducing the influence of inductance noise Wire the voltage detection cable for the base metal away from the cable of base metal For easier handling cut the voltage detection cable for base metal si...

Page 42: ...ollowing points Bundle both the base metal cable and the torch cable and apply tape on them Straighten the cables as much as possible If you cannot straighten the cables as explained run the torch cab...

Page 43: ...B and wind them in the same manner times of winding and diameter 2 Pile the bundle A on the bundle B Pile them so that their winding directions are opposite 3 Connect the bundles A and B with a wire...

Page 44: ...etal Connect the connectors as same as above In using the welding power source for TIG welding prepare a welding torch by the customer Contrary to the normal connection the TIG welding requires connec...

Page 45: ...en them in the clockwise direction 2 Connect the cable for welding electrode holder side to the output terminal torch side Connect the connectors as same as above In using the welding power source for...

Page 46: ...Supply Be sure to observe the following points to prevent from suffocation due to gas leakage or explosion Be sure to turn off the shielding gas at the main tap when the welding power source is not in...

Page 47: ...ck due to leakage of electricity may occur Be sure to install a switch with fuse or a circuit breaker for motor to the input side of each welding power source Otherwise electric shock and fire due to...

Page 48: ...cable of the welding power source to the breaker Capacity of the disconnect switch and the rating of fuse and circuit breaker are appropriate 3 1 1 Welding power source equipment Perform grounding for...

Page 49: ...ol cable for wire feeder BKCPJ 1010 10 m For details on cables see 2 2 3 2 Details on extension cables and hoses 7 Cable at torch side BKPDT 8012 10 m 8 Cable at base metal side BKPDT 8012 10 m 9 Gas...

Page 50: ...inals stops output of the welding power source When combining switches use a push lock turn reset switch for preventing accidental reset 5 9 IN EXT1 External input 1 Reserve inputs for expanding termi...

Page 51: ...ctric shock ensure to follow the instructions below Wiring should be performed by qualified persons or persons familiar with the welding machine Do not touch the input and output terminals and the int...

Page 52: ...1 mm from the end while pressing the button on the terminal block and insert the cable 5 Check the wiring and place the cover for external connection back to the welding power source The control cable...

Page 53: ...tection cable set the internal function F38 to ON 6 7 1 Setting procedure Details on the internal function F38 6 7 2 24 F38 Arc voltage direct detection switching 4 6 1 Wiring to wire feeder This sect...

Page 54: ...t detection terminal at the base metal side of the welding power source 1 Check that input power is turned off with the disconnect switch connected to the welding power source 2 Connect the voltage de...

Page 55: ...pplied with a power feeding brush to the positioner Insulate the power feeding brush from the jig base and connect the voltage detection cable base metal side to the jig base TIPS Before wiring the vo...

Page 56: ...WIRING OF VOLTAGE DETECTION CABLE AT BASE METAL SIDE CONNECTION CHAPTER 4 4 22...

Page 57: ...ilation equipment does not give sufficient performance ensure to use respiratory protective equipment For preventive measure from falling due to anoxia apply lifelines such as a safety belt For the we...

Page 58: ...rom spatter and spattering dross Wear protective equipment such as protective leather gloves long sleeve clothes leg covers and leather apron Ignoring the above may cause electrical shock and burn Ins...

Page 59: ...e shield gas flow rate as follows MAG gas MIG gas 10 to 25L min 15 to 25L min 11 When the shield gas is mixed each gas pressure should be the same Set pressures of the respective gas to the same level...

Page 60: ...torch cable has no bending at a sharp angle If the liner is clogged with dirt or when inched wire has flaw replace the liner with a new one In replacing the liner follow the precautions on the attache...

Page 61: ...n the main tap of shielding gas When the gas regulator is equipped with a pressure gauge open the main tap by checking the pressure gauge until the appropriate pressure is obtained Handle the gas cyli...

Page 62: ...imately 10 mm Releasing the WIRE INCH key will stop the wire feeding For excessive wire cut the wire using a plier Turning the parameter adjusting knob during the wire feeding can adjust the feed spee...

Page 63: ...ntal change of the welding conditions the erroneous operation prevention function is equipped for the operations other than inching gas check or reading saving of the welding condition In using the an...

Page 64: ...e metal In DC STICK welding arc start requires setting of the welding electrode in the electrode holder and contact of the electrode with the base metal 2 A series of welding operation is completed by...

Page 65: ...press the CURRENT SETTING DISPLAY SWITCH key to light up the LED In the adjustment by the remote control this operation is not necessary Turn the parameter adjustment knob for the remote control the...

Page 66: ...elding end This section explains the supply stop procedure of power shielding gas after the welding end 1 Close the main tap of the shielding gas 2 Press the GAS CHECK key The LED of the GAS CHECK key...

Page 67: ...Voltage INDIVIDUAL 10 0 to 40 0 V 23 5 V Voltage SYNERGY 100 to 100 0 Post flow time 0 to 10 sec 0 4 sec Set the gas discharge time after the welding ends Arc spot time 0 1 to 10 sec 3 sec Set the we...

Page 68: ...e welding condition F7 Down slope time 0 0 to 10 0 0 0 s Sets the slope time from the welding condition to the crater condition F8 Welding result display time 0 to 60 20 s Sets the display time for th...

Page 69: ...ing 0 4 0 Sets the functions of output terminal of the programmable I O F26 External output 2 setting F27 External output 3 setting F28 External output 4 setting F29 External input 1 setting 0 to 9 0...

Page 70: ...ase and decrease by double clicking 100 to 100 0 A Sets current increase decrease volume by double clicking of the torch switch available when ON is selected in F48 F51 Special crater repeat OFF ON OF...

Page 71: ...ratio of wire feeder speed in wave pulse welding F67 Setting change of current value initial condition crater condition OFF ON OFF When CRATER ON is selected sets the current value of the initial con...

Page 72: ...elding voltage according to the welding current is regarded as 0 based on which the welding voltage is finely adjusted 6 DISPLAY CHANGE SWITCH key Switches the welding sequence as the set target Durin...

Page 73: ...When the wire diameter which cannot be used is selected the LED flashes 6 6 1 Welding mode setting 15 CRATER FILL key Select the crater treatment method or arc spot at the end of welding The LED of th...

Page 74: ...UST key is on SYNERGIC mode The welding voltage is automatically set according to the set welding current To fine tune welding voltage adjust the synergic fine adjustment knob When the LED of the VOLT...

Page 75: ...le to be registered are 100 at maximum Single welding condition can contain the following information at registration Welding mode selected by the keys on operation panel Shielding gas Wire Crater Pen...

Page 76: ...ic data stored by this function are susceptible to occurrence of static electricity impact repair etc and there is a possibility that the stored contents may be changed or lost BE SURE TO MAKE A COPY...

Page 77: ...lues are displayed on the left right digital meters in a flashing mode To change the JOB No to register press the SAVE key The display returns to the status described in step 1 To cancel the memory re...

Page 78: ...E key depressed together turn ON the power switch The LED of ENTER key flashes Pressing the DISPLAY CHANGE key enables to check the set values of welding conditions welding parameters to read out The...

Page 79: ...turn the parameter adjustment knob counterclockwise to display ALL on the right digital meter When ALL is selected the current welding condition set on the operation panel is also deleted and the weld...

Page 80: ...MIG 2 5 CO2 1 2 CrNi 1 0 1 2 2 CrNi Ferr 1 0 1 2 2 MIG 2 O2 1 3 CrNi 1 0 1 2 2 MAG 20 CO2 1 4 G3Si1 1 0 1 2 2 DC WAVE PULSE MIG 100 Ar 1 1 Al 99 1 0 1 2 1 6 2 Al Mg 1 0 1 2 1 6 2 MIG 2 5 CO2 1 2 CrNi...

Page 81: ...e DC wave pulse 50 to 250 AC pulse AC wave pulse 40 to 200 1 6 DC 100 to 350 DC pulse DC wave pulse 75 to 350 AC pulse AC wave pulse 60 to 300 SOFT ALUMINUM A4043 etc 1 2 DC 90 to 250 DC pulse DC wave...

Page 82: ...uence initial condition and crater fill condition can be added depending on the crater setting The welding parameters such as gas discharge time welding current and voltage should be set to this seque...

Page 83: ...On A Off and the value displayed on the left digital meter switches to the display of wire feed speed Pressing the CURRENT SETTING DISPLAY SWITCH key again to light on the LED of the key m min Off re...

Page 84: ...main welding 6 6 3 1 Crater OFF CRATER FILL ON Unavailable After the main welding the welding process on the Crater condition is available 6 6 3 2 Crater ON no initial condition Available Adding to th...

Page 85: ...he welding operation In the second ON operation the welding sequence is carried out by the crater current Even if the torch switch is switched off during welding the signal will be self hold The torch...

Page 86: ...the second ON operation enables the welding by the crater current Even if the torch switch is switched off during welding the signal will be self hold The torch switch should remain depressed and held...

Page 87: ...on again within 2 seconds the machine starts on the Crater condition and continues operation Repeating this allows crater process to be carried out as many times as needed ON ON OFF ON OFF OFF ON OFF...

Page 88: ...on the nozzle for arc spot see the instruction manual of the torch 6 6 5 Welding voltage adjustment This section explains how to adjust the welding voltage The adjustment of welding voltage can be car...

Page 89: ...le it is likely that good welding can be performed by adjusting it to hard 6 6 7 EN ratio In the AC pulse welding the EP current the torch is polarity and the EN current the torch is polarity output a...

Page 90: ...Aluminum welding makes a ripple bead using an overlap method It can also make welding easier even if there is a gap between weld parts because it performs a crystal miniaturization by vibrating the mo...

Page 91: ...mes small and has no effect The amount of molten material is related to the bead size When weld is performed using a thick bead the effect becomes large This effect is not for disappearing blowholes i...

Page 92: ...ER 6 6 26 3 Turn the parameter adjustment knob and change the setting value 4 Press the WAVE FRQ key or the DISPLAY CHANGE key Adjustment of wave frequency is complete Adjust the value between 0 5 to...

Page 93: ...tions TIPS The internal function is activated at the point when the setting value is changed To change the set values of internal functions ensure that there is no mistake in the function No as well a...

Page 94: ...ashing when setting to ON OFF Standard mode TIPS In using the welding power source in the HIGH mode the setting of this function is set to OFF and cannot be changed When the status is not improved eve...

Page 95: ...process Welding current voltage setting Set by operation panel or remote control Set by external command voltage 2 Set by operation panel or remote control Inching Operation by operation panel or remo...

Page 96: ...ing from the initial current to the welding current upslope time longer Setting range of upslope time 0 0 to 10 0 sec Supply 0V to 15 V to E1 and E2 Exceeding 15 V may result in damage to the control...

Page 97: ...6 8 Operation of Analog Remote Control Optional When using the remote control in a low current region set the scale plate to 200A 6 7 2 10 F10 Motor overcurrent detection level Set the over current de...

Page 98: ...enabled or Either of the internal functions F29 to F32 External input terminal setting is set to either 4 Start or 5 Loading welding condition Internal function F4 Auto Semi auto mode is set to a val...

Page 99: ...adhesion to the base material can be prevented The shape of wire tip can be arranged to obtain a stable start of the next welding The time and voltage for anti stick process are automatically set to a...

Page 100: ...ted duty cycle OFF The cooling fan rotates in a control mode power saving operation due to the temperature detection inside the welding power source This mode is effective in saving power consumption...

Page 101: ...d speed with the maximum command voltage is 22 m min Depending on the welding mode the wire feed speed does not always reach 22 m min The minimum wire feed speed is approximately 0 6 to 2 0 m min This...

Page 102: ...ch ON 3 5 Loading welding condition The welding conditions stored on the memory can be read out by combination of signals 4 5 6 DC PULSE switch Short circuit between terminals allows DC welding mode O...

Page 103: ...turning the two signals of the external input terminal IN EXT2 IN EXT3 to ON enable to read out the JOB No 7 For F29 and F32 other functions can be set 5 Even after reading out the welding condition...

Page 104: ...s to the registered JOB No The condition can not be changed during welding To release the JOB shift mode release the external input terminals The digital meter displays current and voltage after 2 sec...

Page 105: ...actual current value The current value displayed on the digital meter is obtained by software processing of the average value of outputs therefore it may not be consistent with the value indicated on...

Page 106: ...ion In the following cases this function cannot be used Welding conditions are not registered to the memory Analog remote control optional is not connected to the welding power source Internal functio...

Page 107: ...o ON enabled or Internal function F51 Special crater repeat is set to ON enabled or Either of the internal function F29 to F32 External input terminal setting is set to 5 Loading welding condition 6 7...

Page 108: ...stment of welding conditions memory is set to 1 to 30 enabled Internal function F44 Reading welding condition with remote control is set to ON enabled Internal function F45 Special crater sequence is...

Page 109: ...y single clicking of the torch switch When this function is enabled the LED of CRATER FILL ON REPEATED of the CRATER FILL key flashes OFF disables the function TIPS When this function is set to ON aut...

Page 110: ...Tack start process This function enables to start the wire feeding speed with the normal feeding speed without slow down after the welding completion which enables the tack welding of less transition...

Page 111: ...left digital meter When LED is ON Absolute value is displayed Values adjusted from the standard value is displayed on the left digital meter For optimum fine adjustment For fine adjustment of unit pul...

Page 112: ...time This function allows fine adjustment of the standard pulse peak time at LOW side in the pulse condition of the wave pulse welding by setting the adjustment value finely adjusted pulse peak time...

Page 113: ...current value of the initial condition can be set in percentage based on the current value of the welding condition Setting range of current value initial condition 10 to 300 6 7 2 47 F69 Setting of c...

Page 114: ...rmed for five seconds after the pre flow Error code E 011 is displayed on the left and right digital meters and the output of the welding power source stops OFF disables the function 9 1 Action in Cas...

Page 115: ...adjustment Optimum welding voltage according to the welding current is automatically set and fine adjustment is available for the set welding voltage Align the welding voltage adjustment knob to the...

Page 116: ...OPERATION OF ANALOG REMOTE CONTROL OPTIONAL WELDING CONDITION CHAPTER 6 6 50...

Page 117: ...ble if the erroneous operation prevention function is disabled NOTE Write down the password on a piece of paper and store it safely The current password will be requested also when you change it If a...

Page 118: ...be requested Hold the two keys pressed down until Loc is displayed on the left digital meter PAS Loc will be displayed in order Release the keys after Loc is displayed If a password has already been s...

Page 119: ...ssword 3 Select the tens place digit and ones place digit in the same manner as the step 2 4 Press the ENTER key Loc flashes on the left digital meter PAS Loc will be displayed in order The hundreds p...

Page 120: ...ption used in welding kg P21 0 0 to 999 Target wire consumption kg P22 0 0 to 5 Operation at the time when the target wire consumption is achieved Total welding time P30 0 Cumulative total welding tim...

Page 121: ...will be cleared according to the P12 setting If continuous operation is enabled the value will be cleared when exceeding 999 and return to 0 P11 Target value of welding points Select the target value...

Page 122: ...red P21 Target wire consumption Select the target value of wire consumption in the range from 0 to 999 kg When the P20 count value reaches the wire consumption specified here an alarm appears indicati...

Page 123: ...ing is monitored When it exceeds the range specified here an alarm displays and the output stops P40 Max fluctuation value of average range monitor If the average current voltage per second becomes ou...

Page 124: ...of output triggered by the torch switch OFF is counted and accumulated as welding time The setting range of count value is between 0 to 999 hours The time between 0 and 99 9 hours are displayed in the...

Page 125: ...trol No P40 flashes on the left digital meter and the difference between the average value and specified value 30 on the right digital meter with the A LED lighting Example While welding is conducted...

Page 126: ...nt welding conditions set with the operation panel will not be saved If necessary record them in memory beforehand The welding condition data recorded in the memory will be output in the way that the...

Page 127: ...rq Wave frequency 0 1 Hz CreIsetPer reserved arc_char2 Arc characteristics reserved TsCrickIset Torch switch urrent adjustment 0 1 OFF ON en_ratio EN ratio 1 CriIsetStep1 Single click adjustment value...

Page 128: ...wing data can be sampled The data types sampling speed should be specified in the internal function F52 F53 data log function 6 7 Setting Internal Functions Simplified data log will be created below t...

Page 129: ...3 3 Failure log function It is possible to record the latest ten error codes The data and time of occurrence will not be recorded The failure log data will be recorded in the DAIHEN_OTC_WELDING_ABN C...

Page 130: ...up 6 Press the LOAD key 7 Press the ENTER key The LED of LOAD key lights up Turn the parameter adjusting knob further counterclockwise to display the data to backup on the right digital meter The disp...

Page 131: ...5 Select the data to import 6 Press the SAVE key 7 Press the ENTER key The LED of SAVE key lights up Turn the parameter adjusting knob further counterclockwise to display the data to import on the rig...

Page 132: ...ll return to the default initial setting 1 Turn off the power switch 2 Press and hold the F function key and GAS CHECK key simultaneously and turn on the power switch 3 Check that End is displayed on...

Page 133: ...e left and right digital meters The display changes every time the F function key is pressed The display order of 5 or later is for manufacturer s management It is not necessary for the user to check...

Page 134: ...CHECKING SOFTWARE VERSION ADMINISTRATOR FUNCTIONS CHAPTER 7 7 18...

Page 135: ...en after the input power is cut Make sure that there is no charged voltage before starting the work During maintenance and inspection take an appropriate measure to prevent turning on the input power...

Page 136: ...ing When using a vacuum cleaner to remove powder dust accumulating on the welding power source do not vacuum between the rotating part of cooling fan and the main body Otherwise lubricant of the beari...

Page 137: ...power source Status of the cooling fan Check that the cooling fan smoothly rotates when the power switch is turned on There should not be sound of metal abnormal vibration or burnt odor While the cool...

Page 138: ...nsumable parts of the welding torch Abnormality in consumable parts can prevent smooth wire introduction Cleaning inside the welding power source Blow with dry compressed air from the front slit venti...

Page 139: ...and Voltage Test If insulation resistance measurement and withstand voltage test is necessary please contact your dealer When measuring insulation resistance and testing withstand voltage follow the s...

Page 140: ...uit between the anode and the cathode For DR6 short circuit between the anode and the cathode Short circuit between TR1 C1 and E1C2 TR2 C2E1 E2 TR3 C1 C2E1 TR4 C2E1 E2 Short circuit between TR5 C1 E1C...

Page 141: ...s on the left right digital meters The welding power source may stop or may not stop output depending on the type of error code The meanings of 1 and 2 in the table below are as follows 1 When the err...

Page 142: ...xceeded the allowable range 1 Check that the input voltage for primary side is between 340 to 460 V The error code will disappear when the power switch is turned off E 160 The input voltage for primar...

Page 143: ...ities in the cables connecting the wire feeder Check that there is no problem in the wire feeder The error code will disappear when the power switch is turned off E 810 The temperature of the governor...

Page 144: ...ic machine mode is selected Check that the setting of internal functions F4 is correct 6 7 2 4 F4 Auto Semi auto mode An analog remote control optional is connected When an analog remote control optio...

Page 145: ...e out Replace the chip 14 Continuous output of the WCR signal is shown on the monitor of the robot The WCR signal is used for communicating with the robot to check the presence of the welding current...

Page 146: ...TROUBLESHOOTING TROUBLESHOOTING CHAPTER 9 9 6...

Page 147: ...module DSEI 2X101 06A 1 DR15 4531 120 Diode D5SB60 1 DR18 4531 710 Diode D1N60 1 DR19 20 4531 119 Diode module DSEI 2X101 06A 2 DR21 22 100 2373 Diode module DSEI 2X101 12A 2 TR1 to 4 100 1750 IGBT m...

Page 148: ...US20X223JBASA 2 C21a to c 4517 401 Ceramic capacitor CS17 F2GA103MYGSA 3 C22a to c 4517 401 Ceramic capacitor CS17 F2GA103MYGSA 3 C23 to 26 Film capacitor US63Y224JAASA 4 CON1 100 1435 Receptacle DPC2...

Page 149: ...4734 007 Output terminal DIX BE 50 70 2 6 100 1736 Handle cover 899 35054 001 1 For NF 7 4739 476 Cap W W02814 2 For CON1 2 8 4735 038 Knob K 100 22RSB 1 Parameter adjustment knob 9 4735 039 Cap K 100...

Page 150: ...REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10 10 4 10 2 1 Schematic diagram...

Page 151: ...10 5 Chapter 10 Reference Materials REFERENCE DRAWING REFERENCE MATERIALS CHAPTER 10...

Page 152: ...P00 P30086S00 P30086V00 DR1 P30086V00 P30205V00 P30087T00 P30086T00 SH DR2 to 9 THP2 R12 13 C12 13 DR21 22 CT2 CT1 PL1 FM1 FM2 FM3 TM5 NF 6 CON1 7 CON2 7 R19a b FM4 TR5 TR6 TR7 TR8 DR19 R66 THP1 DR20...

Page 153: ...feeding length is too long The arc length becomes long The bead width becomes wide Shielding becomes poor The wire feeding length is too short The arc length becomes short Spatter is generated The we...

Page 154: ...8 1 250 29 to 30 35 12 0 10 1 180 to 200 25 to 27 45 2 180 to 200 25 to 28 45 3 180 to 200 25 to 28 45 16 0 12 1 220 to 230 25 to 28 45 2 220 to 230 25 to 28 45 3 210 to 220 25 to 28 45 Plate thicknes...

Page 155: ...ravel speed cm min 6 0 1 170 25 to 26 30 2 180 26 to 27 30 9 0 1 270 29 to 30 30 2 290 30 to 31 30 12 0 1 280 30 to 31 40 2 330 33 to 34 40 19 0 1 300 31 to 32 45 2 300 31 to 32 45 1 340 32 to 33 45 2...

Page 156: ...illation 120 times min Bevel shape Number of layers Current A Voltage V Remarks 1 100 20 to 21 Slight oscillation 2 280 26 to 27 Slight oscillation 3 280 26 to 27 Slight oscillation 4 280 26 to 27 Sli...

Page 157: ...rent A Voltage V Travel speed cm min Wire feeding length mm Gas flow rate L min 1 5 1 2 60 to 80 16 to 18 60 to 80 12 to 15 20 2 0 1 2 70 to 80 17 to 18 40 to 50 15 20 3 0 1 2 80 to 100 17 to 20 40 to...

Page 158: ...MATERIALS FOR SETTING WELDING CONDITIONS REFERENCE MATERIALS CHAPTER 10 10 12...

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Daihen OTC Welbee Inverter W400, Owner'S Manual

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